Smart Axis Automatic Chasing Machine Manual

SMART AXIS
AUTOMATIC CHASING MACHINE

SECTION CONTENTS PAGE NO
1 SPECIFICATION AND DATA 3
2 PACKING,FOUNDATION,LEVELLING,ALIGNING 4
AND GROUTING
3 LUBRICATING INSTRUCTION 5
4 MAINTENANCE 6
5 OPERATION 7
6 RECOMMENDED SPARES 9
7 TROUBLE SHOOTING 12
DRAWING NO. DRAWINGS AND PARTS LIST

811 00 300 GENERAL ASSEMBLY 14
811 01 350 BED ASSEMBLY 17
811 02 350 HEAD STOCK ASSEMBLY 18
811 03 350 SADDLE ASSEMBLY 20
811 04 350 FEED ASSEMBLY 22
811 05 350 LEAD SCREW ASSEMBLY 24
811 06 350 THREE ROLLER SUPPORT ASSEMBLY 26
811 07 350 INDEXING STOPPER ASSEMBLY 27
811 00 401 FOUNDATION DRAWING 28
811 10 401 ELECTRICAL CIRCUIT 29

Smart Axis Automatic Chasing Machine

INVIEW OF CONTINUOUS PROCESS OF PRODUCT DEVELOPMENT THE DESIGN OF THE MACHINE
IS SUBJECTED TO CHANGE WITHOUT PRIOR NOTICE

Please Note:
For any correspondence regarding this machine and while ordering spares, please mention
the following:

MACHINE NO :________________ YEAR :____________

CUSTOMER :________________
2

SECTION 1

SPECIFICATION AND DATA

1.1 OVERALL DIMENSIONS

Length : 3350 MM
Width : 1190 MM
Height : 1530 MM

1.2 MOTORS

Description Power RPM
Main drive 3.75 KW (5HP) 1440
Coolant Pump 0.10 KW (0.13 HP) 2900
AC SYN Motor 0.36KW(0.48HP) 60

1.3 SPINDLE / ROLLER SPEED

FOR ROLLER DIA RPM
Dia 8.25” & 8.5” 14 to 16
Dia 9.5” 10 to 12
Dia 13” 8 to 10

1.4 ELECTRICAL DATA

ABB MPCB Recommended
FL
Motor HP Frame Relay Range Back‐up Fuse rating
Amps
(Amps) (Amps)
Main drive 112M 8 ‐ 6
5HP(3.75 KW)

Coolant 63/4 0.34 0.4 – 0.63 2
Motor

3
SECTION 2

PACKING, FOUNDATION, LEVELLING
ALIGNING AND GROUTING

2.1 PACKING :

Packing is done in crates and boxes, unpainted surfaces are given a protective coat
which needs to be removed at the time of assembly.

Please check number of packages and the contents there of against the packing list sent
with the consignment. For breakages / shortage obtain transporters certificate. Inform
insurer and manufacturer immediately.

Store in a safe place free from rain and dust to avoid damage to bearings and other
components.

2.2 FOUNDATION:

Refer to foundation detail on Page: 28

Pockets should be left as shown for the foundation bolts. For the correct position of the
pockets, use wooden frames.

2.3 LEVELLING,ALIGNING AND GROUTING:

 Place the foundation bolts in the pockets.
 Place the two pedestals over their respective blocks.
 Put the screed plates under the Jack bolts.
 Level the Bed with the help of spirit level and grout the foundation bolts with 1:2:4
concrete mixtures in the respective pockets.
 Allow minimum 4 days setting time and keep replenishing with curing water.
 Tighten the foundation bolts. Check the level again and adjust with the help of jack
bolts if there is any error.

4

SECTION 3

LUBRICATING INSTRUCTION

Type of
SI.NO. Lubrication Points Frequency Quantity
Lubrication
Head Stock Running
1. *Oil 1500‐2000 10 Liters.
hrs.
Linear Guide ways & 4‐5 Strokes of Oil
2. *Oil Daily
blocks gun
Main ball screw & 4‐5 Strokes of Oil
3. *Oil Daily
Cross lead screw gun
4. Motor Bearings *Grease 4000 Running hrs Replenish Grease
5. Tail stock Bearing *Oil Daily 4‐5 Strokes
6. Lead screw Bearing *Grease Weekly Replenish Grease
7. Spindle bearing *Oil Daily 4‐5 Strokes

Feed rod gear box
8. *Oil Daily 4‐5 Strokes
chain sprocket
9. Tool feeding cam assy *Oil Daily 4‐5 Strokes
10. Indexing assy *Oil Daily 4‐5 Strokes

 Grease : Multipurpose Grease
 Oil : Servo 140 / Alpha 617 / Metamol 68 / Bharat MP

3.1 COOLANT:

 Use soluble cutting oil of IOL or equivalent quality.
 Coolant reservoir should be cleaned before filling with coolant. The level of the
coolant is to be periodically checked and the pump and pipe are to be cleaned every
month.

5
SECTION 4

MAINTENANCE

PROPER MAINTENANCE WILL INCREASE THE LIFE AND EFFICIENCY OF THE MACHINE. A
THOROUGH WEEKLY CLEANING IS VERY ESSENTIAL FOR ANY MACHINE IN CONTINUOUS
USE. ANY DEFECT, HOWEVER SMALL SHOULD IMMEDIATELY BE ATTENDED OTHERWISE,
THE SAME MAY LEAD TO MAJOR BREAKDOWN OF THE MACHINE. RESULTING IN LOSS OF
PRODUCTION AND HIGH COST OF REPAIRS.

4.1 ELECTRICAL

Electrical equipment is the life of the machine. Please study the following instructions for
proper maintenance and use of equipment:

 Before commissioning the machine, Please tighten loose wires, if any:
 The insulation resistance of the motor windings between each terminal and earth
must be checked. This should be more than one mega OHM. This test should be
done on the machine on its arrival and when starting after prolonged period of
shutdown.
 Care should be taken to prevent the ingress of dust, moisture or foreign material
into the electrical elements.
 Static elements like connectors, fuses etc, need periodic cleaning. Please inspect
and tighten all terminal connections.
 Elements like contactors, switches, etc should be cleaned after every 1500 operating
hours. If contacts are pitted, clean with brush and apply a thin coating of petroleum
jelly.
 After every 4000 hours of operation, check the grease in motor bearings. Bearings
should be cleaned with pure benzene. After drying rinse them in spindle oil, heat to
about 50 degree centigrade and then lubricate them with about 9.5 cubic cms of
lithium based grease.
 After 8000 hours of operation, the motor should be overhauled.
 Check the function of all the three proximity switches and limit switches periodically.

6

SECTION 5

OPERATION

5.1 MECHANICAL

PRE STARTING CHECK UP

 Ensure that the gear box is filled with recommended oils up to the mark indicated on
the respective oil level indicators.

 Move the carriage to the extreme right end (tail stock end) and set the chaser in such a
way that half an inch(12.7mm) of a chaser is in contact with the roller with one of its
tips in line with the roller edge in order to get a chamfered end (full tooth)

 Set the stopper rod 1 and stopper rod 2 in engaged position (as shown in fig.1) in
withdrawn condition of the tool

Figure.1

 The limit switches and proximity switches on the rear side should be positioned
according to the roller length.

 Start the spindle motor.

7

 Move the chaser against the roller step by step to get the required depth being in three
or four backward and forward automatic movement of the chaser.
5.2 ELECTRICAL

Working Operation of SMART AXIS CHASING MACHINE in Auto Mode

For details circuit refer page 29,30,31

 Sensor (R1) fixed in the feed rod gives signal to the servomotor.

 The servomotor rotates the lead screw by one rotation. Hence the saddle move by
0.5inch. This process continues for the length of the roller.

 The depth of chasing is automatically after initial setting is done manually

 R2 sensor on the left side of the bed to the right end cut off the forward movement of
saddle to the left

 To bring the saddle to the right end turn the selector switch to “Syn.motor”.

 To run the coolant motor turn the selector switch to “Coolant motor”.

8

SECTION 6

RECOMMENDED SPARES

S.NO PART NO. DESCRIPTION QTY
1 811 03 416 COMPRESSION SPRING 2 NOS
2 811 03 423 BACKLASH SPRING 2 NOS
3 811 07 401 STOPPER ROD 1 1 NO
4 811 07 402 STOPPER ROD 2 1 NO
5 811 07 407 INDEXING SPRING 2 NOS
6 SAXMCP000001 COOLANT PUMP 1 NO
7 SAXMBRGNJ305 THREE ROLLER SUPPORT BEARING (NJ 305) 4 NOS
8 SAXMBRGIN608 TRACER BEARING (INDEXING)-608 2 NOS
9 SAXMBRGF6012 TRACER BEARING (FEED)-6012 1 NO
10 SAXMCHU4J001 4 JAW CHUCK 1 NO
11 SAXMBC000001 FLEXIBLE BELLOW CLOTH 2 NOS
12 SAXEPRE00001 SINGLE PHASE PREVENTER (SELEC 800 PSR) 2 NOS
13 SAXECONT0001 CURRENT CONTROLLER EL MEASURE 1 NO
14 SAXEDIS00001 RPM DISPLAY (SELEC PIC 101) 2 NOS
15 SAXEHM000001 HOUR METER 1 NO
16 SAXEPRS00001 PROXIMITY SWITCH 2 NOS
17 SAXESYMOT001 SYNCHRONISED MOTOR 1 NO
18 SAXECPFAN001 CONTROL PANEL BOARD COOLING FAN 1 NO
MAIN DRIVE GEARBOX WITH FLANGED 3 Ph
19 SAXMGBFL0001 1 NO
MOTOR
20 SAXERELAY001 SALZER 24C DC RELAY 2 NOS
21 SAXESMPS0001 SMPS 230V-24V 1 NO
22 SAXETRA00001 150V TRANSFORMER 1 NO
23 SAXELS000001 LIMIT SWITCH 1 NO
24 SAXEMPCB0001 mpcb (0.40-0.63) (ABB) 1 NO

NOTE : REFER SADDLE ASSEMBLY AND INDEXING ASSEMBLY DRAWINGS FOR PART NOS
811 03 416 , 811 03 423 , 811 07 401 , 811 07 402 AND 811 07 407.

9

LOCATION OF RECOMMENDED SPARES – SMART AXIS CHASING MACHINE
10

11
LOCATION OF RECOMMENDED SPARES – CONTROL PANEL
12

SECTION 7
13

TROUBLE SHOOTING

Apparent Problems Portable causes Suggested Remedies
MECHANICAL

Vibration  Play in spindle bearing  Reset or / Tighten
 Tool is blunt  Re sharpen the tool
 Tool holder over hanging  Set Properly
 Roller clamping is not proper  Check three roller support
 Linear slide assy loose  Check and replace if required

Indicated high motor Tool blunt Resharpen
current

Tools get Soft tool Change the tool
blunt very frequently Hard roller Reduce roller RPM

ELECTRICALS

Motor does not start  Failure of incoming supply  Check the incoming voltage at
 Failure of control voltage, terminals
fuses blown out or contactors  Checkup contactors, fuses etc.,
not functioning

Motor noisy  Fan of the motor may be loose  Tighten fan.
 Motor bearing failure  Replace bearings

Burning of motor  Failure of overload protection  Check overload relay and its
setting.

Ball screw not rotating  Proximity switch not  Check proximity switch and the
functioning sensor point

Carriage over shots the  Proximity switch not  Check and correct or replace
proximity functioning

14
15

GENERAL ASSEMBLY ‐ 811 00 300
16

BACK VIEW

17

GENERAL ASSEMBLY – PART LIST
PART NO. DESCRIPTION QTY
1 BED ASSEMBLY 1 Assy
2 HEADSTOCK ASSEMBLY 1 Assy
3 SADDLE ASSEMBLY 1 Assy
4 FEED ASSEMBLY 1 Assembly
5 LEAD SCREW ASSEMBLY 1 Assy
6 THREE ROLLER ASSEMBLY 1 Assembly
7 INDEXING STOPPER ASSEMBLY 1 assy
8 CHUCK 1 No
9 MAIN DRIVE 1 No
10 CHIP TRAY 1 No
11 COOLANT TANK 1 No
12 CONTROL PANEL 1 No
13 FEEDER ROD DRIVE 1 No
14 TOOL FEEDING 1 No

18

19

BED ASSEMBLY ‐811 01 350

S.NO DRAWING NO DESCRIPTION QTY

1 811 01 201 BED 1
2 811 01 302 FRONT PEDESTAL 1
3 811 01 303 REAR PEDESTAL 1

20

HEADSTOCK ASSEMBLY ‐ 811 02 350
21

22

23
SADDLE ASSEMBLY ‐ 811 03 350
24

25

FEED ASSEMBLY ‐ 811 04 350
26
27
28

LEAD SCREW ASSEMBLY ‐ 811 05 350

29
30

31

THREE ROLLER SUPPORT ASSEMBLY ‐ 811 06 350
32

INDEXING SUPPORT ASSEMBLY ‐ 811 07 350
33

FOUNDATION DRAWING ‐ 811 00 401
34

35
ELECTRICAL CIRCUIT DRAWINGS ‐ 811 10
401
36
37
38

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SMART AXIS

AUTOMATIC CHASING MACHINE

DRAWING NO. DRAWINGS AND PARTS LIST

5. Tail stock Bearing *Oil Daily 4‐5 Strokes

6. Lead screw Bearing *Grease Weekly Replenish Grease

7. Spindle bearing *Oil Daily 4‐5 Strokes

10. Indexing assy *Oil Daily 4‐5 Strokes

PART NO. DESCRIPTION QTY

10 CHIP TRAY 1 No

11 COOLANT TANK 1 No

12 CONTROL PANEL 1 No

13 FEEDER ROD DRIVE 1 No

14 TOOL FEEDING 1 No

S.NO DRAWING NO DESCRIPTION QTY

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